GOALI: Modeling and Design of Composite Web Roll-to-Roll Systems

该奖项的研究目标是为在卷筒到卷筒(RTR)制造系统中制造和加工的复合腹板开发基本的腹板行为动态模型。复合网是由不同的单独柔性材料层或通过在基层上应用厚凝胶材料而形成的。除了开发模型外，一个相关的核心目标是设计RTR系统的配置(从动辊、卷筒纸导向器和传感系统的位置选择)以及RTR机器部件的相关协调控制策略，从而能够制造出缺陷更少的高质量复合纤网。研究方法是利用第一原理开发现实的纤网动力学模型，该模型可以预测复合纤网形成期间的观察到的行为及其随后通过加工机械的传输。将对这些模型进行分析，以开发有效配置RTR系统的基本元素的方法。该项目还将为原始元素开发新的基于模型的控制策略，以控制关键工艺变量，如纸幅张力、运输速度和横向位置。交付内容包括复合网络模型、RTR系统的建模和分析工具、通过软件和硬件进行演示和验证、研究结果文档、工程专业学生教育以及对实习工程师进行现代方法和技术培训。如果成功，这项研究的结果将为制造产品质量更高、损耗更少、成本更低的复合网提供方法。重点将放在复合地板和天花板产品上，但开发的方法和工具将足够通用，可用于制造各种其他现有的消费网络产品，如纸巾、塑料薄膜、卫生产品等。将研究应用于开发使用RTR制造的柔性电子产品等新消费产品的潜力也很大。工程专业的研究生和本科生将通过与实践工程师的互动和参与工业现场的应用研究活动而受益。国际合作将促进研究进展，并将为工科学生提供与外国同行互动的机制。

The research objective of this award is to develop fundamental dynamic models of web behavior for composite webs that are manufactured and processed in roll-to-roll (RTR) manufacturing systems. Composite webs are formed from dissimilar individual flexible material layers or through application of a thick gel material onto a base layer. In addition to developing models, a related core objective is to design the configuration (selection of location of driven rollers, web guides, and sensing systems) of the RTR systems and associated coordinated control strategies for RTR machine elements that would enable manufacture of quality composite webs with fewer defects. The research approach is to develop realistic models of web dynamics using first principles that can predict observed behavior during the formation of the composite web and its subsequent transport through processing machinery. The models will be analyzed to develop methods to efficiently configure primitive elements of RTR systems. The project will also develop new model-based control strategies for primitive elements to control key process variables such as web tension, transport velocity and lateral position. Deliverables include composite web models, modeling and analysis tools for RTR systems, demonstration and validation via software and hardware, documentation of research results, engineering student education, and training of practicing engineers in modern methods and technologies. If successful, the results of this research will provide methods to manufacture composite webs with improved product quality, less wastage, and reduced cost. The focus will be on composite flooring and ceiling products but the methods and tools developed will be general enough for use in manufacture of a wide variety of other existing consumer web products such as paper tissues, plastic film, hygiene products, etc. The potential for application of the research to development of new consumer products such as flexible electronics using RTR manufacturing is also substantial. Graduate and undergraduate engineering students will benefit through interactions with practicing engineers and involvement in applied research activities at the industrial site. International collaboration will enhance research progress and will provide a mechanism for engineering students to interact with foreign counterparts.